Solid fuel from brown grease and methods and systems for brown grease and sewage sludge recycling

ABSTRACT

A method and system for making solid fuel from brown grease includes providing brown grease, dewatering the brown grease, and combining the dewatered brown grease with a combustible material under conditions effective to make a solid fuel. A method and system for making a fertilizer material from sewage sludge includes providing sewage sludge, providing steam generated by combusting a fuel comprising brown grease, and contacting the sewage sludge with the steam under conditions effective to dewater the sewage sludge and render a fertilizer material.

FIELD OF THE INVENTION

The present invention generally relates to methods and systems forrecycling grease and sewage sludge and, more particularly, to methodsand a system for making a solid fuel from brown grease and solid fuelsthereof, as well as a method and system for making a fertilizer materialfrom sewage sludge.

BACKGROUND

Brown grease, generally known as trap grease, is a waste productgenerated in large part by food preparation and food servicesfacilities. Failure to properly collect, remove, and dispose of browngrease at these and other facilities can result in accumulation inbuilding piping, municipal collection systems, wastewater treatmentplants, and onsite system drain fields. These accumulations can causeblockage and are known to frequently interfere with subsequent treatmentplant sludge disposal or pass through treatment plants fouling dischargewaters. Accumulated brown grease can also plug up trickling filters andother process equipment and has been known to kill drainage fields vitalto the disposal process. Escaping brown grease in outflow and sludge canserve as transport and growth support for pathogenic organisms,resulting in contamination of lakes, rivers, beaches, and groundwater.

In view of these hazards, public health and safety laws regulate thecollection, removal, and disposal of brown grease from brown greasegenerating facilities. These regulations typically require that browngrease be collected, removed, and properly disposed of. Collection ofbrown grease waste is generally carried out in on-site grease traps,grease interceptors, and/or other grease removal devices. Grease trapsare relatively small devices hooked directly to the outgoing drains ofsinks and dishwashers and are generally located inside the foodpreparation or food services facilities. Because they hold relativelysmall quantities of captured grease, these traps must be emptied andcleaned on a regular basis to avoid overflow. Grease interceptors arerelatively large underground devices usually located outside the browngrease generating facility and are connected to the outgoing sewerdrainage system. Grease interceptors must also be regularly emptied andcleaned.

Removal of brown grease from collection devices is typically performedby commercial septic haulers, which transport the collected brown greaseto a proper disposal site. Disposal of brown grease generally requiresthat the brown grease be processed so that it can no longer enter theenvironment (water, soil, or air) in a form or quantity as to bedeleterious. The most widely used methods of brown grease disposalinclude composting, caking for landfill deposit, land application,incineration, and blending or treating the brown grease at municipaltreatment works.

Collecting, removing, and disposing of accumulated brown grease can bean expensive operation. Typically, producers of brown grease waste hirea private commercial waste hauler to regularly empty and clean greaseremoval devices and transport the brown grease to a suitable disposalsite. With recent increases in fuel prices, transporting collected browngrease to disposal sites has placed increased economic burdens on boththe commercial septic haulers and the food preparation and food servicesfacilities that generate brown grease waste and pay for thetransportation and disposal services. The most widely used disposalmethods can cost as much as 20 cents to 85 cents per gallon dependingupon locale and disposal options available. Thus, as fuel and energyprices continue to rise and as generation of brown grease wastecontinues to increase, there is a need to develop cost-effective methodsand systems for brown grease disposal.

Bioremediation methods for brown grease disposal have recently beensuggested as an alternative to traditional methods of brown greasecollection, removal, and disposal. Onsite bioremediation refers tobioremediation at the site of brown grease generation prior to removalto a disposal site. Bioremediation systems are essentially a septictank-drain field combination. The advantages of bioremediation of browngrease include (i) elimination of the need for frequent cleaning anddisposal of brown grease; (ii) reduction of the brown grease pollutantto its basic elements (carbon, hydrogen and oxygen), usually in theforms of carbon dioxide and water; and (iii) removal of food scraps fromfacility effluent for useful by-products. However, bioremediationsystems require complex engineering to develop tailored systems and canbe expensive to operate and maintain.

Recycling methods and systems are also being developed as alternativesto traditional methods and systems of brown grease disposal. Forexample, a process for separating grease trap waste and other restaurantand commercial grease waste into their principal components, namelygrease, water and solids, and reclaiming at least the solids and greasecomponents has previously been disclosed in U.S. Pat. No. 5,225,085 toNapier et al. The solids from this process are said to have substantialcommercial value usable in animal and pet foods.

Another technique for recycling brown grease is described in U.S. PatentApplication Publication No. 2003/0201226 to Kelly, which discloses aprocess and apparatus for the treatment of septage, particularly greasetrap waste. According to this process, septage is treated upon arrivalat the processing facility by screening and grinding the raw septage.After the initial treatment, the septage is stored within a receivingtank prior to being transferred to a pasteurization tank. The septage ispasteurized by the introduction of steam into the tanks. Afterpasteurization, the septage is transferred to cooling tanks. The cooledpasteurized septage is then transferred to filter press feed tanks whereit is treated with an alkali substance such as lime. The added alkaliacts as a filter aid and allows the septage to be more easily dewateredinto a good filter cake. The resulting lime conditioned septage slurryis pumped through filter presses that separate the solids from theliquid. Sludge dropped from the filter presses is said to havebeneficial use as a biosolid to provide nutrients to growing vegetationor to improve the quality of soil for the purpose of growing vegetation.

Accordingly, to date brown grease recycling methods have focused ondisposal of brown grease by generating foodstuff and biosolid materialsfor agricultural use. There continues to be a need for cost-effectivemethods and systems for recycling brown grease waste that provideadequate and proper disposal and produce revenue-generating productsthat help to reduce or eliminate the cost of collection, removal, anddisposal.

Another waste product that could benefit from cost-effective recyclingmethods and systems is sewage sludge. Sewage sludge is a “solid”by-product of wastewater treatment systems, which must be removed fromtreated wastewater streams and undergo dewatering and drying proceduresbefore being useable as a land application Biosolid fertilizer. Theprocedures of sewage sludge dewatering and drying typically involvemechanical dewatering systems and thermal drying operations.

One such thermal drying operation involves indirect contact dryers inwhich the heating of the sludge is indirectly affected by heatingsurfaces. Depending on the type of dryer, these heating surfaces possessthe form of discs, paddles, rolls, and the like. Typically, the heatingsurfaces are steam-heated heating surfaces that heat the sludge untilthe moisture contained in the sludge evaporates. A ventilator or blowersucks away resulting exhaust vapors. The sludge dried in this manner iseither applied to the heating surfaces in a thin layer and then abrasedor scraped off, or the heating surfaces are moved or stirred in theproduct to be dried.

Generating the steam to heat the heating surfaces in these systemstypically involves a fuel boiler that consumes large amounts of fuel. Inview of increasing fuel costs, there continues to be a need forcost-effective and environmentally friendly fuel sources to provide theenergy needed to recycle sewage sludge into commercially beneficialproducts, such as Biosolid fertilizer materials.

SUMMARY

A method for making solid fuel from brown grease in accordance withembodiments of the present invention includes providing brown grease,dewatering the brown grease, and combining the dewatered brown greasewith a combustible material under conditions effective to make a solidfuel.

A system for making solid fuel from brown grease in accordance withother embodiments of the present invention includes a dewatering unitand a mixing unit. The dewatering unit dewaters brown grease and themixing unit combines the dewatered brown grease with a combustiblematerial under conditions effective to make a solid fuel from thedewatered brown grease.

A solid fuel in accordance with other embodiments of the presentinvention includes brown grease and at least one combustible materialcombined with the brown grease to make a solid fuel.

A method for generating energy from brown grease in accordance withother embodiments of the present invention includes dewatering browngrease. The dewatered brown grease is combusted under conditionseffective to generate energy.

A method for making solid fuel from brown grease in accordance withother embodiments of the present invention includes providing browngrease and dewatering the brown grease under conditions effective tomake a solid fuel.

A solid fuel in accordance with other embodiments of the presentinvention includes dewatered brown grease.

A method of making a fertilizer material from sewage sludge inaccordance with other embodiments of the present invention includesproviding sewage sludge. Steam is provided by combusting a fuelcontaining brown grease. The sewage sludge is contacted with the steamunder conditions effective to dewater the sewage sludge and render afertilizer material.

A system for making fertilizer material from sewage sludge in accordancewith other embodiments of the present invention includes a system formaking solid fuel from brown grease, which includes a dewatering unitcapable of dewatering brown grease under conditions effective to make asolid fuel. The system of the invention has a solid fuel boiler capableof combusting solid fuel from the system for making solid fuel togenerate steam. The system also has a steam dryer for dewatering sewagesludge, where the steam dryer is coupled to the solid fuel boiler,whereby steam from the solid fuel boiler contacts the steam dryerthereby dewatering sewage sludge contained in the steam dryer to rendera fertilizer material.

The present invention provides a number of advantages, includingproviding alternative, cost-effective methods and systems for disposalof brown grease waste. More specifically, the present invention helpsmeet the demands of disposing of an increasing amount of brown greasewaste being generated by food processing and food services facilities,which is particularly significant in view of rising costs associatedwith brown grease waste disposal. Further, by providing safe andenvironmentally friendly methods and systems for utilizing the browngrease, the present invention helps prevent contamination of fresh watersupplies and helps reduce the spread of harmful biological contaminates.

The present invention also provides methods and systems for not onlydisposing of brown grease, but making a revenue-generating solid fuelfrom this waste product. This solid fuel can be sold for profit or asexplained herein can be utilized as a cost-effective energy source formaking a fertilizer from sludge. This provides significant conservationbenefits, as well as fuel cost savings at sludge-processing wastetreatment facilities.

Accordingly, these and other advantages, which will be apparent to thoseof ordinary skill in the art, are provided by the present invention.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a block diagram of a system for making solid fuel from browngrease in accordance with embodiments of the present invention;

FIG. 2 is a flowchart of a method for making solid fuel from browngrease in accordance with embodiments of the present invention;

FIG. 3 is a block diagram of a system for making a fertilizer materialfrom sewage sludge in accordance with embodiments of the presentinvention; and

FIG. 4 is a flowchart of a method for making a fertilizer material fromsewage sludge in accordance with embodiments of the present invention.

DETAILED DESCRIPTION

A system 8 for making solid fuel from brown grease in accordance withembodiments of the present invention is illustrated in FIG. 1. Thesystem 8 includes a process vat 14, a base treatment supply system 16, apolymer treatment supply system 18, a dewatering unit 20, a separatedliquid vat 22, a mixing unit 24, a combustible material supply system26, and a processing control system or controller 30, although system 8could comprise other numbers and types of devices and systems in otherconfigurations. The present invention provides a number of advantagesincluding providing a system and methods for converting brown greasewaste into a beneficial solid fuel and for utilizing this solid fuel asa cost-effective energy source for making a fertilizer from sludge.

Referring more specifically to FIG. 1, the process vat 14 is an opencontainer constructed of stainless steel, although other types andnumbers of containers which are constructed of other types of materialscan be used. The process vat 14 can hold several thousand gallons ofbrown grease, although the size of the process vat 14 can vary based onthe particular application. The process vat 14 is capable of mixing orstirring the contents contained in process vat 14.

A supply line 32 with a valve 34 is connected to the process vat 14 andis used to supply brown grease from a delivery truck 12 to the processvat 14, although other manners of supplying the brown grease to processvat 14 can also be used. The control valve 34 is coupled via signallines 76 and 54 to the controller 30 which controls the operation of thevalve 34 between an open and a closed state to regulate the supply ofbrown grease being supplied to process vat 14, although other mannersfor controlling the valve 34 can be used, such as by manually turningthe valve 34. Additionally, although in this particular embodiment asupply line 32 and a valve 34 are shown, the supply lines of this andother systems of the invention can comprise other numbers and types ofdevices, such as filters, pumping devices, and other pipes and valves.Additionally, other types of transfer systems, such as conveyer belts,can be used.

A sensor 40 is connected to the process vat 14 to monitor and detect thepH, temperature, consistency, and other physical and/or chemicalproperties of the material contained in process vat 14, although othernumbers and types of sensing devices that can monitor and detect otherproperties can be used. Sensor 40 is coupled to processing controlsystem 30 via signal lines 58 and 54 which uses the monitored anddetected readings from sensor 40 to control the operation of valves 34and 46. Controller 30 may also use readings from sensor 40 to controlthe operation of valve 48, which regulates the transfer of polymertreatment, as described in greater detail below.

Process vat 14 is coupled to base treatment supply system 16 via supplyline 78. Base treatment supply system 16 is a container that holds abase treatment (described below) although other types of configurationsmay also be used. Control valve 46 is positioned in supply line 78 andregulates the transfer of base treatment from base treatment supplysystem 16. Valve 46 is coupled via signal lines 56 and 54 to thecontroller 30, which controls the operation of the valve 46 between anopen and a closed state to regulate the transfer of base treatment beingsupplied to process vat 14, although other manners for controlling thevalve 46 can be used, such as manually controlling the valve 46.

System 8 includes polymer treatment supply system 18, which is acontainer that supplies a polymer treatment via supply line 70, althoughother types of configurations of polymer treatment supply system 18 canbe used. Transfer of material through supply line 70 is regulated byvalve 48, which is coupled to controller 30 via signal lines 60 and 54so that controller 30 can control the operation of the valve 48 betweenan open and closed state to regulate the transfer of polymer treatmentto supply line 36. Although a valve 48 whose operation is controlled bycontroller 30 is shown, other manners for controlling the valve 48 canalso be used. In this particular embodiment, polymer treatment frompolymer treatment supply system 18 is meter pumped through supply line70.

Dewatering unit 20 is coupled to process vat 14 to receive materialtransferred from process vat 14 via supply line 36. Dewatering unit 20is a system or device capable of separating liquid and solid componentsof processed brown grease. Suitable dewatering units include units orsystems that are well-known by those of ordinary skill in the art forseparation procedures and include, without limitation, mechanicalseparators, chemical separators, and/or thermal separators. Mechanicalseparators typically involve a centrifuge, a belt filter press, or agravity dewatering container. Chemical separators employ a chemicalreaction between different compounds. Thermal separators heat browngrease to cause evaporation of water content. In this particularembodiment, dewatering unit 20 of system 8 is a centrifuge, althoughother dewatering units or systems may also be used, such as a gravitydewatering container.

In this particular embodiment, supply line 36, by which material entersdewatering unit 20 for processing, is operably connected to a positivedisplacement pump with meter control. Supply line 36 may be equippedwith one or more valves, as necessary, to control the flow of materialfrom process vat 14 to dewatering unit 20. These valves may be coupledto processing control system 30 which controls the operation of thevalves between an open and a closed state to regulate the transfer ofmaterial from the process vat 14 to the dewatering unit 20 throughsupply line 36. Other manners for controlling the valves and/or materialflow can be used.

A sensor 42 is connected to the dewatering unit 20 to monitor and detectthe consistency (e.g., the % water content) and other physical and/orchemical properties of the material contained in dewatering unit 20.Other numbers and types of sensing devices which can monitor and detectother properties can also be used. Sensor 42 is coupled to processingcontrol system 30 via signal lines 64 and 54. Processing control system30 uses the monitored and detected readings from sensor 42 to controlthe operation of valve 50 positioned in supply line 72. The controlvalve 50 is also coupled to the controller 30, via signal lines 62 and54, to provide control of the operation of the valve 50 between an openand a closed state to regulate the transfer of separated liquid fromdewatering unit 20 to separated liquid vat 22. Separated liquid vat 22may be connected to a collection source, whereby the liquid istransferred for further processing or disposal. In an alternativeembodiment, system 8 may have a supply line leading directly fromdewatering unit 20 to a wastewater stream.

System 8 also has a mixing unit 24 which is coupled to dewatering unit20 via supply line 38. Mixing unit 24 is an industrial strength mixercapable of mixing the dewatered material from dewatering unit 20 with acombustible material from combustible material supply system 26.Combustible material is transferred from combustible material supplysystem 26 to mixing unit 24 via supply line 74. Mixing unit 24 is, inthis particular embodiment, a ribbon mixer, although other types ofmixers can be employed. Combustible material supply system 26 is acontainer that holds combustible material, although other configurationsof combustible material supply system 26 can be used. Valve 52 ispositioned in supply line 74 and is coupled to processing control system30 via signal lines 66 and 54, whereby processing control system 30 canoperate the open and closed state of valve 52, although other manners ofoperating valve 52 can be used.

Sensor 44 is connected to mixing unit 24 to monitor and detect theconsistency (e.g., the ratio of dewatered brown grease to combustiblematerial) and other physical and/or chemical properties of the materialcontained in mixing unit 24. Other numbers and types of sensing devicesthat can monitor and detect other properties can be used. Sensor 44 iscoupled to processing control system 30 via signal lines 68 and 54.Processing control system 30 uses the monitored and detected readingsfrom sensor 44 to control the operation of valve 52 and informs theoperator of the properties of solid fuel product 28, although theoperation of the valve 52 can be controlled in other manners, such aswith manual controls.

Processing control system 30 of system 8 is used to control operationsin the system 8 for making a solid fuel from brown grease. Theprocessing control system 30 includes a central processing unit (CPU) orprocessor, a memory, and an interface system which are coupled togetherby a bus or other link, although other numbers and types of each of thecomponents and other configurations and locations for the components canbe used. The processor in the processing control system 30 shown in FIG.1 executes a program of stored instructions for one or more aspects ofthe present invention as described herein, including instructions formaking a solid fuel from brown grease. The memory stores theseprogrammed instructions for one or more aspects of the present inventionas described herein, although some or all of the programmed instructionscould be stored and/or executed elsewhere. A variety of different typesof memory storage devices, such as a random access memory (RAM) or aread only memory (ROM) in the system or a floppy disk, hard disk, CDROM, or other computer readable medium which is read from and/or writtento by a magnetic, optical, or other reading and/or writing system thatis coupled to the processor, can be used for the memory in themanagement server system. The interface system in the processing controlsystem 30 is used to operatively couple and communicate between theprocessing control system 30 and the valves 46, 48, 50, and 52 and thesensors 40, 42, and 44, although other types of connections to othernumbers and types of components which can provide data and/or becontrolled could be used.

A method for making solid fuel from brown grease in accordance withembodiments of the present invention is illustrated in FIG. 2. Themethod of the invention is carried out using the system of theinvention, including the embodiment illustrated in FIG. 1, althoughother embodiments or systems can be used in carrying out the method.

In step 100, brown grease, also known as trap grease, is received from acommercial septic hauler that collects brown grease waste from foodpreparation or food processing facilities. Brown grease is typicallycollected in these facilities in grease traps, grease interceptors, andother grease collection units, although other sources of brown greaseare known and can be used in carrying out the method. In system 8 ofFIG. 1, brown grease 10 is received from delivery truck 12 into processvat 14 through supply line 32. Processing control system 30 controls thetransfer of brown grease 10 from septic hauler 12 to process vat 14 byregulating the open and closed state of valve 34 in supply line 32.Other manners of transferring brown grease from a delivery truck orother source into processing vat 14 can be used. If necessary, pumps,filters, and/or other transport components may be used to transfer browngrease into system 8. Once the brown grease is received into process vat14, it is processed immediately, although the grease could be stored andprocessed at a later time.

In step 102, a base treatment is applied to the brown grease. Applying abase treatment elevates the pH of the brown grease and improves theconsistency of the brown grease to facilitate later processing. Browngrease typically has a pH of about 4. When the pH of brown grease israised to at least about 8.5, the gummy consistency of brown grease isbroken down to a slurry, although the threshold to which the pH israised can be adjusted as necessary. This slurry is more suitable forcarrying out later steps of this particular embodiment than the gummierraw brown grease with a lower pH. In system 8 of FIG. 1, base treatmentis applied to the brown grease in process vat 14 from base treatmentsupply system 16 via supply line 78. Processing control system 30controls the transfer of base treatment through supply line 78 byregulating the open and closed state of valve 46, via signal lines 56and 54. Other ways of introducing a base treatment into process vat 14may also be used. In this particular embodiment, base treatment is mixedor stirred with the brown grease contents in process vat 14.

In step 104, it is determined if the brown grease has achieved a pH ofgreater than or equal to 8.5. Other threshold levels of pH may also beset according to the present method, including pH levels equal to orabove about 9.0, 9.5, or 10. Determining the pH of a material is aprocedure commonly practiced and known by persons of ordinary skill inthe art. In system 8 illustrated in FIG. 1, detection of the pH of thebrown grease is determined by sensor 40, which detects and/or monitors,either continually or periodically, the pH of the brown grease andcommunicates this information to processing control system 30 via signallines 58 and 54. If processing control system 30 receives a signal fromsensor 40 which indicates that the pH of the brown grease is not equalto or greater than the pre-set level (e.g., 8.5, although other pre-setlevels could be determined), the “no” branch of step 104 is taken andprocessing control system 30 maintains valve 46 in an open state tocontinue to supply base treatment to process vat 14. When processingcontrol system 30 receives a signal that the brown grease in process vat14 has achieved a pH of equal to or greater than the pre-set value, the“yes” branch is taken and processing control system 30 adjusts valve 46to a closed state, thus terminating the transfer of base treatment tothe brown grease contained in process vat 14.

In step 106, a polymer treatment is applied to the brown grease.Treatment with a polymer solution has the beneficial effect of creatingcharges in the water and thereby accelerating and increasing separationof water from grease. In this particular embodiment, the brown grease istreated with a cationic emulsion polymer solution, although othersuitable polymer treatments are known and can also be used. In system 8of FIG. 1, polymer treatment is applied to brown grease from polymertreatment supply system 18 via supply line 70. As shown, supply line 70connects to supply line 36, whereby polymer treatment comes into contactwith brown grease as it is being transferred from process vat 14 todewatering unit 20, although polymer treatment may be applied at otherpoints of processing brown grease in system 8. Processing control system30 controls the transfer of polymer treatment through supply line 70 byregulating the open and closed state of valve 48, via signal lines 60and 54 in response to stored amounts in control system 30, althoughother manners for regulating the amount of polymer treatment applied,such as based on manual control of the valve 48 or based on operatorinput into the control system 32. Other manners of bringing a polymertreatment in contact with brown grease can be used.

In step 108, the brown grease is dewatered. Dewatering brown greaseinvolves separating the liquid components in brown grease from the solidcomponents. Dewatering may involve separation procedures that arewell-known in the art including, without limitation, mechanicalseparation, chemical separation, and/or thermal separation. In system 8of FIG. 1, brown grease is transferred out of process vat 14 via supplyline 36 to dewatering unit 20, where it is dewatered. Pumps and/or otherdevices capable of transferring liquid or solid material may bepositioned in process vat 14, supply line 36, dewatering unit 20, or anyother component of system 8 to transfer the processed brown grease fromprocess vat 14 to dewatering unit 20, and throughout system 8 asnecessary. These components can be controlled by processing controlsystem 30 via signal lines, as desired and based on information receivedby processing control system 30 from the sensors of system 8, althoughother manners for controlling these components can be used, such asmanually controlling one or more of these components.

Liquid that is separated during the dewatering process is transferredout of dewatering unit 20 via supply line 72 into separated liquid vat22 and is subsequently transferred out of separated liquid vat 22 anddisposed of. In an alternative embodiment, separated liquid leavesdewatering unit 20 via a supply line that leads directly to a sewagestream. The transfer of separated liquid out of dewatering unit 20 iscontrolled by processing control system 30, which regulates the open andclosed state of valve 50 via signal lines 62 and 54. As the brown greaseis being dewatered, sensor 42 detects and/or monitors the % solidcontent of the brown grease being dewatered in dewatering unit 20 andrelays this information to processing control system 30. Accordingly,the transfer of liquid out of dewatering unit 20 may be automaticallycontrolled by processing control system 30, although other manners oftransferring liquid from the dewatering unit can be used, such as bemanually controlling valves related to the transfer of the liquid.

In step 110, a determination of whether the dewatered brown grease hasachieved approximately a 50% solid content is made. Other % solidcontent values, including ranges, may be substituted for 50%. In thisparticular embodiment, the solid content of the dewatered brown greaseis 30% solid content or higher, although other ranges may also besuitable. According to the particular embodiment of FIG. 1, the step ofdetermining whether the % solid content of the dewatered brown greasehas achieved the desired level is carried out using sensor 42. Sensor 42detects and/or monitors, either continuously or periodically, the %solid content of the dewatered brown grease and communicates thisinformation to processing control system 30 via signal lines 64 and 54.Determining whether the % solid content of the dewatered brown greasehas achieved the desired level can also be carried out in other manners,such as by a manual, visual inspection or with the aid of instruments.In step 110, if it is determined that the dewatered brown grease has notachieved approximately a 50% solid content (or any other pre-determinedsolid content), the “no” branch is taken and the brown grease is furtherprocessed in the dewatering unit. When it is determined that thedewatered brown grease has achieved the desired % solid content, thenthe “yes” branch is taken in step 110.

In step 112, the dewatered brown grease is combined with a combustiblematerial. Combining dewatered brown grease with a combustible materialmay be carried out in a mixing unit, such as a ribbon mixer, althoughother manners of mixing and other types and numbers of mixing units orcontainers can be used. Combustible materials suitable for carrying outthe method include, without limitation, sawdust, wood chips, andcombustible trash materials, such as municipal solid waste, paper pulp,and construction and demolition material, although other materials mayalso be used. Although dewatered brown grease is capable of being usedas a fuel, combining the dewatered brown grease with a combustiblematerial may provide the benefit of preventing the build-up of carbonaround the edges of the solid fuel which can prevent combustion. Theaddition of combustible material to the dewatered brown grease providesspacing to allow oxygen into the brown grease fuel to enhance burningand prevent smoldering. In this particular embodiment, mixing is carriedout in mixing unit 24 until the combined material achieves a ratio ofdewatered brown grease to combustible material of 2:1, by weight or byvolume, although other ratios of dewatered brown grease to combustiblematerial may also be used depending on the % solid content of thedewatered brown grease, the type of combustible material selected forcombining with the dewatered brown grease, and the intended use.

As illustrated in system 8 of FIG. 1, dewatered brown grease that hasachieved the desired ratio of liquid to solid components is transferredout of dewatering unit 20 to mixing unit 24 via supply line 38. In thisparticular embodiment, supply line 38 is a conveyer belt or any otherdevice capable of transferring solid material, such as a concrete pumpor a screw auger. The particular device used to transfer material fromdewatering unit 20 to mixing unit 24 may depend on the consistency ofthe dewatered brown grease.

Combustible material is supplied to mixing unit 24 from combustiblematerial supply system 26, and is transferred via supply line 74. Theamount of combustible material entering mixing unit 24 from combustiblematerial supply system 26 is controlled by processing control system 30,which operates the open and closed state of valve 52 via signal lines 66and 54, although other manners for controlling the valve 52 can be used,such as with manual control. Processing control system 30 operates valve52 in response to communications received from sensor 44, via signallines 68 and 54. Sensor 44 detects and/or monitors, either constantly orperiodically, the ratio of dewatered brown grease to combustiblematerial in mixing unit 24.

In step 114, a determination is made whether the ratio of dewateredbrown grease to combustible material (e.g., 2:1, by weight or volume,although other ratios could be used) has been obtained. In thisparticular embodiment, a sensor 44 relays information pertaining to theconsistency and/or other properties of the brown grease in mixing unit24 to processing control system 30 via signal lines 68 and 54.Processing control system 30 uses this information to determine whetherto further open or close the valve 52 which regulates the transfer ofcombustible material through supply line 74, although other manners ofcarrying out this step can be used. If it is determined that thecombined dewatered brown grease and combustible material has notachieved the proper ratio, then the “no” branch is taken in step 114 andthe amount of combustible material and/or dewatered brown grease isadjusted. When it is determined that the ratio of dewatered brown greaseto combustible material has achieved the proper ratio, then the “yes”branch is taken and in step 116 the solid fuel is output.

Solid fuel 28 is a solid fuel capable of generating energy throughcombustion. If desired, solid fuel 28 can be compressed and/or formedinto any desirable shape or size. For example, solid fuel 28 can be inthe form of compressed pellets, logs, bricks, or loose piles, althoughother forms can also be used. In other applications, the solid fuel 28may be dried in a drier. Supplemental materials may also be added to thedewatered brown grease along with the combustible material to enhancesolid fuel 28. Suitable supplemental materials may include combustionenhancers, odor suppressors or enhancers, or any other supplement, asdesired.

Accordingly, as described herein the present invention provides a numberof advantages, including alternative, cost-effective methods and asystem for disposal of brown grease waste. The methods and system of thepresent invention help meet the demands of disposing of an increasingamount of brown grease waste being generated by food processing and foodservices facilities, which is particularly significant in view of risingcosts associated with brown grease waste disposal. The solid fuelproduced by the methods and system of the present invention provide aclean, alternative fuel source. This advantage is particularlysignificant as oil supplies continue to deplete and demand for energycontinues to rise.

In this particular embodiment, the solid fuel produced by the methodsand system of the present invention provides a beneficial fuel sourcefor sewage sludge disposal and methods and systems of recycling sewagesludge into a BioSolid fertilizer material. Thus, another aspect of thepresent invention relates to a system for making fertilizer materialfrom sewage sludge. Referring to FIG. 3, a system 118 for making afertilizer material from sewage sludge in accordance with embodiments ofthe present invention is illustrated. The system 118 includes a solidfuel boiler 122, a steam drier 136, and a processing control system orcontroller 150, although system 118 could comprise other numbers andtypes of devices and systems in other configurations. This aspect of thepresent invention provides a number of advantages including providing acost-effective method and system for converting sewage sludge waste intoa beneficial fertilizer material. In addition, the present inventionprovides a recycling system for sewage sludge waste that can be operatedon the solid fuel of the present invention.

The solid fuel boiler 122 provides system 118 with a source of steamwhich can be used for drying sewage sludge pursuant to the operation ofsystem 118. Solid fuel boilers rely on solid fuel as a source of energyto produce steam, although other types of fuel, such as liquid and/orgaseous fuel could be used as well. Solid fuel boilers are well known inthe art and any solid fuel boiler of industrial strength and capacitycan be selected for use in accordance with system 118 of the presentinvention. Solid fuel boilers are intended to include any type ofcombustion system or device which uses solid fuel as at least a portionof the energy source.

In this particular embodiment, solid fuel boiler 122 receives solid fuel28 via supply line 120, although other manners for supplying the fuelcan be used. Supply line 120 can be an actual supply line, e.g., aconveyer belt or other tubing or transport system for solid fuel, orsupply line 120 can be optional if it is more desirable to manually addsolid fuel into solid fuel boiler 122. Solid fuel boiler 122 is equippedwith sensor 124, which can monitor and detect conditions within solidfuel boiler 122, such as temperature, although other manners formonitoring the temperature can be used. Sensor 124 is coupled toprocessing control system 150 via signal lines 126 and 128 which usesthe monitored and detected readings from sensor 124 to control valve132, although other manners for controlling the valve 132 can be used,such as by manually controlling the valve 132. Although signal lines 126and 128 are shown to couple sensor 124 to controller 150, other mannersof coupling this and other units of system 118 to controller 150 andother manners for coupling the controller 30 to valves, sensors, andother components in the earlier embodiment can be used, such as via awireless communication system.

The steam produced in solid fuel boiler 122 is transferred out of solidfuel boiler 122 into steam drier 136 via supply line 130. Supply line130 is equipped with valve 132, which regulates the transfer of steamfrom solid fuel boiler 122 to steam drier 136, although other manners ofregulating steam transfer can be used. Valve 132 is coupled toprocessing control system 150 via signal lines 134 and 128, wherebyprocessing control system 150 regulates the open and closed state ofvalve 132 in response to signals received from sensor 124. In analternative embodiment, valve 132 is a manually operated valve.

Steam drier 136 is, in this particular embodiment, an indirect contactdryer in which sewage sludge can be dried with heating surfaces.Depending on the type of dryer, these heating surfaces possess the formof discs, paddles, rolls, and the like, although other types of dryersthat use steam can be used. Steam drier 136 receives sewage sludge 158for drying via supply line 160, although other manners for supplying thesewage sludge can be used. Supply line 160 and the other supply lines ofsystem 118 can be fitted with a valve and/or one or more pumps ifdesired. Supply line 160 can also be connectable to a sewage sludgesupply source at a waste treatment facility, or a delivery truck.

A sensor 144 is connected to steam drier 136 to monitor and detect,continually or periodically, conditions within steam drier 136. In thisparticular embodiment, the sensor 144, detects the percentage of solidcontent of the sewage sludge contained in steam drier 136, althoughother numbers and types of sensing devices that can monitor and detectother conditions can be used. Sensor 144 is coupled to processingcontrol system 150 via signal lines 146 and 128.

In this particular embodiment, the steam drier 136 has a ventilator orblower that sucks away resulting exhaust vapors from within steam drier136, although other manners for venting exhaust gases can be used.Exhaust vapors 156 exit steam drier 136 via supply line 138, which inthe embodiment illustrated in FIG. 3 is equipped with valve 140 toregulate the flow of exhaust vapors 156 from steam drier 136. Valve 140is coupled to processing control system 150 via signal lines 142 and 128whereby processing control system 150 regulates the open and closedstate of valve 150 in response to information from the sensor 144,although other manners for controlling the valve 140 can be used, suchas by manually controlling the valve 140. Dried sewage sludge is removedfrom steam drier 136 via supply line 148, which is capable oftransferring dried sewage sludge as fertilizer 152 to delivery vehicle154.

Processing control system 150 of system 118 is used to controloperations in system 118 for making a fertilizer material from sewagesludge, and has the features described above for the processing controlsystem of the system illustrated in FIG. 1, although other manners forcontrolling the operation can be used, such as manually controllingoperations.

A method for making a fertilizer material from sewage sludge inaccordance with embodiments of the present invention will now bedescribed with reference to FIGS. 1-4. In step 162, solid fuel isreceived, at least a portion of which is solid fuel made from browngrease in accordance with the present invention. In system 118 of FIG.3, solid fuel 28 is transported from a system 8 of making solid fuelfrom brown grease of the present invention. It may be desirable for thesystem 8 of making solid fuel from brown grease of the present inventionto be located in close proximity to the system 118 for making afertilizer material from a sewage sludge of the present invention. Thisway solid fuel from the system of making solid fuel from brown grease ofthe present invention can easily be transferred/transported to supplyenergy for the operation of the system for making a fertilizer materialfrom sewage sludge of the present invention. According to an embodiment,the two systems are coupled and reside in the same treatment plantfacility. The present invention provides the advantage of using a systemand method for recycling brown grease to produce a solid fuel productthat can provide a supply of fuel to a method and system for recyclingsewage sludge to make a fertilizer material.

In system 118 of FIG. 3, solid fuel from the methods and system ofmaking a solid fuel from brown grease of the present invention isreceived into solid fuel boiler 122 through supply line 120. If needed,a valve can be positioned in supply line 120 to regulate the transfer ofsolid fuel into solid fuel boiler 122. In particular embodiments, supplyline 120 is a conveyer belt, auger, or other supply line fortransferring solid materials. If necessary, pumps filters, and/or othertransport components may be positioned in supply line 120. In analternative embodiment, supply line 120 signifies a pathway of materialtransfer, which is carried out manually by shovel or some other transfersystem.

In step 164, solid fuel is delivered to a solid fuel boiler where, instep 166, solid fuel is combusted to provide steam. In system 118illustrated in FIG. 3, solid fuel boiler 122 is equipped with sensor124, which detects and/or monitors, either continually or periodically,the conditions within solid fuel boiler 122 and relays this informationto processing control system 150 via signal lines 126 and 128. Forexample, sensor 124 may detect and/or monitor the internal temperatureof solid fuel boiler 122 and/or provide an indication of the amountand/or temperature of steam being produced by solid fuel boiler 122.

In step 168, steam is transferred from a solid fuel boiler to a steamdrier. In system 118 illustrated in FIG. 3, steam is transferred fromsolid fuel boiler 122 to steam drier 136 via supply line 130. Valve 132is positioned in supply line 130 to regulate the transfer of steam fromsolid fuel boiler 122 to steam drier 136. In the embodiment illustratedin FIG. 3, valve 132 is coupled to processing control system 150 viasignal lines 134 and 128, whereby the open and closed state of valve 132is regulated. In this particular embodiment, the open and closed stateof valve 132 is regulated by processing control system 150 in responseto signals received from sensor 124 via signal lines 126 and 128.

In step 170, sewage sludge is added to a steam drier where, according tostep 172 of the method, sewage sludge is dried. In system 118illustrated in FIG. 3, sewage sludge 158 is transferred to steam drier136 via supply line 160. Sewage sludge is typically obtained directlyfrom a wastewater treatment facility, or from a delivery truck. Steamsupplied to steam drier 136 via supply line 130 is applied to heatingsurfaces of steam drier 136, which may be in the form of discs, paddles,rolls, and the like. Sewage sludge 158 can be applied to the heatingsurfaces in a thin layer and then be abrased or scraped off, or theheating surfaces can be moved or stirred in sewage sludge 158. Othertechniques of drying using steam can be used. Typically, the heatingsurfaces are steam-heated heating surfaces that heat the sludge untilthe moisture contained in the sludge evaporates. In this particularembodiment, steam drier 136 is a steam paddle drier.

According to an embodiment, steam drier 136 has a ventilator or blowerthat sucks away resulting exhaust vapors 156, via supply line 138. Asillustrated in FIG. 3, valve 140 may be positioned in supply line 138 toregulate the transfer of exhaust vapors 156 from steam drier 136.Processing control system 150 regulates the open and closed state ofvalve 140 via signal lines 142 and 128 in response to signals receivedfrom sensor 144 via signal lines 146 and 128. In an alternativeembodiment, valve 140 is a manually operated valve.

In step 174, it is determined whether the sewage sludge in the steamdrier has obtained a % solid content (e.g., about 90% solids, or anyother suitable amount). If the sewage sludge in the steam drier has notobtained the desired % solid content, the “no” branch is taken and thesewage sludge remains in the steam drier for further drying. If thesewage sludge in the steam drier has obtained the desired % solidcontent, the “yes” branch is taken and the dried sludge is transferredto a delivery vehicle in step 176. In system 118 illustrated in FIG. 3,sensor 144 is used to monitor and/or detect whether the sewage sludge insteam drier 136 has reached the desired amount of % solids. When thesewage sludge in steam drier 136 reaches the desired amount of % solids,it can be transferred out of system 118 via supply line 148. The driedsewage sludge is then in the form of fertilizer material 152, which canbe loaded onto vehicle 154 and transported to a suitable site for landapplication as a Biosolid fertilizer. In this particular embodiment, thefertilizer is a class A Biosolid fertilizer.

Having thus described the basic concept of the invention, it will berather apparent to those skilled in the art that the foregoing detaileddisclosure is intended to be presented by way of example only, and isnot limiting. Various alterations, improvements, and modifications willoccur and are intended to those skilled in the art, though not expresslystated herein. These alterations, improvements, and modifications areintended to be suggested hereby, and are within the spirit and scope ofthe invention. Additionally, the recited order of processing elements orsequences, or the use of numbers, letters, or other designationstherefore, is not intended to limit the claimed processes to any orderexcept as may be specified in the claims. Accordingly, the invention islimited only by the following claims and equivalents thereto.

1. A method of making solid fuel from brown grease, said methodcomprising: providing brown grease; dewatering the brown grease; andcombining the dewatered brown grease with a combustible material underconditions effective to make a solid fuel.
 2. The method according toclaim 1 further comprising adding a base to the brown grease prior tosaid dewatering under conditions effective to raise the pH of the browngrease.
 3. The method according to claim 2, wherein the pH of the browngrease is raised to a pH above about 8.5.
 4. The method according toclaim 2, wherein the base is lime.
 5. The method according to claim 1further comprising treating the brown grease with a polymer solution. 6.The method according to claim 5, wherein the polymer solution comprisesa cationic emulsion.
 7. The method according to claim 1, wherein thedewatered brown grease contains about 50% solids.
 8. The methodaccording to claim 1, wherein the combustible material is sawdust.
 9. Asolid fuel comprising: brown grease and at least one combustiblematerial combined with the brown grease.
 10. The solid fuel according toclaim 9, wherein the brown grease is dewatered brown grease.
 11. Thesolid fuel according to claim 10, wherein the dewatered brown greasecontains about 50% solids.
 12. The solid fuel according to claim 9,wherein the brown grease has a pH above about 8.5.
 13. The solid fuelaccording to claim 9, wherein the brown grease and the combustiblematerial are present in the solid fuel in a ratio of about two partscombustible material to about one part brown grease by volume or byweight.
 14. The solid fuel according to claim 9, wherein the combustiblematerial is sawdust.
 15. A method of generating energy from browngrease, said method comprising: dewatering brown grease and combustingthe dewatered brown grease under conditions effective to generateenergy.
 16. The method according to claim 15 further comprising adding abase to the brown grease prior to said dewatering under conditionseffective to raise the pH of the brown grease.
 17. The method accordingto claim 16, wherein the pH of the brown grease is raised to a pH aboveabout 8.5.
 18. The method according to claim 15 further comprisingtreating the brown grease with a polymer solution prior to saiddewatering.
 19. The method according to claim 18, wherein the polymersolution comprises a cationic emulsion.
 20. The method according toclaim 15, wherein the dewatered brown grease contains about 50% solids.21. The method according to claim 15 further comprising combining thedewatered brown grease with a combustible material prior to saidcombusting.
 22. The method according to claim 21, wherein the browngrease and the combustible material are combined in a ratio of about twoparts combustible material to about one part dewatered brown grease byvolume or by weight.
 23. The method according to claim 21, wherein thecombustible material is sawdust.
 24. The method according to claim 21,wherein the combined dewatered brown grease is baked under conditionseffective to render a combined dewatered brown grease having about 90%solids.
 25. A system for making solid fuel from brown grease, saidsystem comprising: a dewatering unit capable of dewatering brown greaseand a mixing unit capable of combining dewatered brown grease with acombustible material to make a solid fuel from dewatered brown grease.26. The system according to claim 25, wherein the dewatering unitcomprises at least one of a mechanical separator, a chemical separator,and a thermal separator.
 27. The system according to claim 25 furthercomprising sensors operably connected to the dewatering unit and themixing unit.
 28. The system according to claim 27 further comprising acontrol system coupled to control the operation of the sensors, thedewatering unit, and the mixing unit, whereby the system is automated.29. A method of making solid fuel from brown grease, said methodcomprising: providing brown grease and dewatering the brown grease underconditions effective to make a solid fuel.
 30. The method according toclaim 29 further comprising adding a base to the brown grease prior tosaid dewatering under conditions effective to raise the pH of the browngrease.
 31. The method according to claim 30, wherein the pH of thebrown grease is raised to a pH above about 8.5.
 32. The method accordingto claim 29, wherein the dewatered brown grease contains about 50%solids.
 33. A solid fuel comprising dewatered brown grease.
 34. Thesolid fuel according to claim 33, wherein the brown grease has a pHabove about 8.5.
 35. A method of making a fertilizer material fromsewage sludge, said method comprising: providing sewage sludge;providing steam generated by combusting a fuel comprising brown grease;and contacting the sewage sludge with the steam under conditionseffective to dewater the sewage sludge and render a fertilizer material.36. The method according to claim 35, wherein the fuel comprises:dewatered brown grease and a combustible material.
 37. The methodaccording to claim 35, wherein said contacting is carried out in a steampaddle dryer.
 38. The method according to claim 35, wherein the sewagesludge is dewatered to contain a minimum of about 90% solids.
 39. Themethod according to claim 35, wherein the fertilizer material is a classA Biosolid fertilizer.
 40. The method according to claim 35 furthercomprising combining ash generated from the combusted fuel with thefertilizer material.
 41. A system for making fertilizer material fromsewage sludge, said system comprising: a system for making solid fuelfrom brown grease, said system comprising a dewatering unit capable ofdewatering brown grease under conditions effective to make a solid fuel;a solid fuel boiler capable of combusting solid fuel from the system formaking solid fuel to generate steam; and a steam dryer for dewateringsewage sludge, wherein the steam dryer is coupled to the solid fuelboiler, whereby steam from the solid fuel boiler contacts the steamdryer thereby dewatering sewage sludge contained in the steam dryer torender a fertilizer material.
 42. The system according to claim 41,wherein the dewatering unit comprises at least one of a mechanicalseparator, a chemical separator, and a thermal separator.
 43. The systemaccording to claim 41, wherein the system for making solid fuel frombrown grease further comprises a mixing unit capable of combiningdewatered brown grease with a combustible material.
 44. The systemaccording to claim 41, wherein the steam dryer is a paddle steam dryer.